Fluid component body and method of making same

ABSTRACT

A method of fabricating a fluid component body includes forming a monolithic fluid component body including a valve segment having an annular upper perimeter wall portion defining a valve cavity and a lower base portion defining first and second flow ports, and a conduit segment extending from one of the first and second flow ports and including a conduit end portion defining a tubular portion extending in a first direction and spaced apart from a remainder of the fluid component body. The conduit end portion is bent from the first direct to a second direction.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. Ser. No.16/445,365, filed on Jun. 16, 2019 which claims priority to and allbenefit of U.S. Provisional Patent Application Ser. No. 62/691,171,filed on Jun. 28, 2018 and entitled FLUID COMPONENT BODY AND METHOD OFMAKING SAME, and U.S. Provisional Patent Application Ser. No.62/801,383, filed on Feb. 5, 2019 and entitled FLUID COMPONENT ANDMETHOD OF MAKING SAME, the entire disclosures of each of which areincorporated herein by reference.

BACKGROUND

Fluid systems often include multiple valves arranged for mixing,switching, purging, and other such controls of one or more types offluid, for example, for gas distribution employed in the manufacture ofsemiconductor wafers. While such fluid control systems may beconstructed by welding or otherwise connecting individual valves in adesired configuration, such arrangements may be undesirable due to thetime and cost of construction, potential leak points at the manyconnections, overall size of the assembly, and other such factors.

Multiple valve manifolds have often been used to address one or more ofthese issues by providing a single body block, machined for desired flowpath arrangements, in which multiple valve assemblies are installed tocontrol flow at multiple points within the multi-ported manifold bodyblock. The manifold body block itself, however, may be expensive anddifficult to machine, and may be limited in the shapes and orientationsof internal ports that may be provided. Additionally, polished surfacefinish requirements for the manifold body flow paths may be difficult tomaintain where the flow paths are extended and/or complex(non-straight).

SUMMARY

In an exemplary embodiment of the present disclosure, a manifold bodyincludes first and second valve segments each comprising an annularupper perimeter wall portion defining a valve cavity and a lower baseportion defining first and second flow ports, wherein the upperperimeter wall of the first valve segment includes a portion that isfused with an adjacent portion of the upper perimeter wall of the secondvalve segment, and a conduit segment defining a fluid flow pathincluding a first leg flow path portion defining a conduit end portionand a second leg flow path portion extending from the first leg flowpath portion to one of the first and second flow ports of the firstvalve segment.

In another exemplary embodiment of the present disclosure, a fluidcomponent body includes an extended fluid flow path having one or morediscontinuities adapted to provide increases in one or more of flowshear, flow compression, and flow incidence when the fluid flow path istreated with an abrasive laden fluid.

In another exemplary embodiment of the present disclosure, a fluidcomponent body includes an internal fluid flow path having a pattern ofsurface discontinuities.

In another exemplary embodiment of the present disclosure, a method offabricating a fluid component body includes forming a monolithic fluidcomponent body including a valve segment having an annular upperperimeter wall portion defining a valve cavity and a lower base portiondefining first and second flow ports, and a conduit segment extendingfrom one of the first and second flow ports and including a conduit endportion defining a tubular portion extending in a first direction andspaced apart from a remainder of the fluid component body. The conduitend portion is bent from the first direct to a second direction.

In another exemplary embodiment of the present disclosure, a method offabricating a fluid component includes forming, using additivemanufacturing, a conduit having first and second portions connected by acentral portion. The central portion of the conduit is bent to reorientthe second portion of the conduit with respect to the first portion ofthe conduit.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages and benefits will become apparent to those skilled inthe art after considering the following description and appended claimsin conjunction with the accompanying drawings, in which:

FIG. 1 illustrates a perspective view of an exemplary diaphragm valvemanifold assembly;

FIG. 1A illustrates a perspective view of the manifold block body of themanifold assembly of FIG. 1;

FIG. 2 illustrates a side cross-sectional view of the manifold assemblyof FIG. 1, taken through the line 2-2;

FIG. 3 illustrates an upper front perspective view of a three-valvemanifold body, in accordance with an exemplary embodiment of the presentdisclosure;

FIG. 3A illustrates a lower rear perspective view of the manifold bodyof FIG. 3;

FIG. 3B illustrates a top plan view of the manifold body of FIG. 3;

FIG. 3C illustrates a bottom plan view of the manifold body of FIG. 3;

FIG. 3D illustrates a front elevational view of the manifold body ofFIG. 3;

FIG. 3E illustrates a rear elevational view of the manifold body of FIG.3;

FIG. 3F illustrates a left side elevational view of the manifold body ofFIG. 3;

FIG. 3G illustrates a right side elevational view of the manifold bodyof FIG. 3;

FIG. 3H illustrates a first cross-sectional view of the manifold body ofFIG. 3;

FIG. 3I illustrates a second cross-sectional view of the manifold bodyof FIG. 3;

FIG. 3J illustrates a bottom perspective view of the manifold body ofFIG. 3, shown in phantom to illustrate additional features of themanifold body;

FIG. 4 illustrates an upper perspective view of a canister mountablefive-valve manifold body, in accordance with an exemplary embodiment ofthe present disclosure;

FIG. 4A illustrates a lower rear perspective view of the manifold bodyof FIG. 4;

FIG. 4B illustrates a top plan view of the manifold body of FIG. 4;

FIG. 4C illustrates a bottom plan view of the manifold body of FIG. 4;

FIG. 4D illustrates a front elevational view of the manifold body ofFIG. 4;

FIG. 4E illustrates a rear elevational view of the manifold body of FIG.4;

FIG. 4F illustrates a left side elevational view of the manifold body ofFIG. 4;

FIG. 4G illustrates a right side elevational view of the manifold bodyof FIG. 4;

FIG. 4H illustrates a first cross-sectional view of the manifold body ofFIG. 4;

FIG. 4I illustrates a second cross-sectional view of the manifold bodyof FIG. 4;

FIG. 4J illustrates a bottom perspective view of the manifold body ofFIG. 4, shown in phantom to illustrate additional features of themanifold body;

FIG. 5 illustrates a perspective view of conduit portion of a fluidcomponent, configured to facilitate bending, in accordance with anexemplary embodiment;

FIG. 5A illustrates the fluid component of FIG. 5, shown undergoing abending operation;

FIG. 6 illustrates the fluid component of FIG. 5, shown in a bentconfiguration;

FIG. 7 illustrates a cross sectional view of an oblong portion of a 3Dprinted conduit, in accordance with an exemplary embodiment;

FIG. 8 illustrates a front view of a conduit portion of another fluidcomponent, configured to facilitate bending, in accordance with anexemplary embodiment;

FIG. 8A illustrates an enlarged partial view of a bendable portion ofthe conduit portion of FIG. 8;

FIG. 9 illustrates the fluid component of FIG. 8, shown in a bentconfiguration;

FIG. 10 illustrates a side view of a conduit portion of another fluidcomponent, shown secured in a bent configuration, in accordance with anexemplary embodiment;

FIG. 11 illustrates a perspective view of an exemplary fluid system flowpath;

FIG. 12 illustrates a perspective view of an exemplary fluid system flowpath having a discontinuous cross-sectional shape, in accordance with anexemplary embodiment of the present disclosure;

FIG. 13 illustrates a perspective view of an exemplary fluid system flowpath having a discontinuous cross-sectional size, in accordance with anexemplary embodiment of the present disclosure;

FIG. 14 illustrates a perspective view of an exemplary fluid system flowpath having a discontinuous cross-sectional central axis, in accordancewith an exemplary embodiment of the present disclosure; and

FIG. 15 illustrates a perspective view of an exemplary fluid system flowpath having a discontinuous cross-sectional shape, size, and centralaxis, in accordance with an exemplary embodiment of the presentdisclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The Detailed Description merely describes exemplary embodiments and isnot intended to limit the scope of the claims in any way. Indeed, theinvention as claimed is broader than and unlimited by the exemplaryembodiments, and the terms used in the claims have their full ordinarymeaning. For example, while specific exemplary embodiments in thepresent application describe multiple diaphragm valve manifolds, one ofmore of the features described herein may additionally or alternativelybe applied to other types of multiple valve manifolds (e.g., bellowsvalves, needle valves, etc.), single valve assemblies, and other fluidsystem components (e.g., pressure regulators, filters, etc.).Additionally, while the geometries and arrangements of many of themanifold body features described herein are such that their productionis facilitated by additive manufacturing, such as 3-D printing, othermanufacturing methods may be utilized to fabricate body componentshaving one or more of the features described herein, such as, forexample, stacked plate assembly, machining, welding, brazing, andcasting (e.g., investment casting, sand casting, lost wax casting),independently or in combination.

While various inventive aspects, concepts and features of the inventionsmay be described and illustrated herein as embodied in combination inthe exemplary embodiments, these various aspects, concepts and featuresmay be used in many alternative embodiments, either individually or invarious combinations and sub-combinations thereof. Unless expresslyexcluded herein all such combinations and sub-combinations are intendedto be within the scope of the present inventions. Still further, whilevarious alternative embodiments as to the various aspects, concepts andfeatures of the inventions—such as alternative materials, structures,configurations, methods, circuits, devices and components, software,hardware, control logic, alternatives as to form, fit and function, andso on—may be described herein, such descriptions are not intended to bea complete or exhaustive list of available alternative embodiments,whether presently known or later developed. Those skilled in the art mayreadily adopt one or more of the inventive aspects, concepts or featuresinto additional embodiments and uses within the scope of the presentinventions even if such embodiments are not expressly disclosed herein.Additionally, even though some features, concepts or aspects of theinventions may be described herein as being a preferred arrangement ormethod, such description is not intended to suggest that such feature isrequired or necessary unless expressly so stated. Still further,exemplary or representative values and ranges may be included to assistin understanding the present disclosure, however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Still further,exemplary or representative values and ranges may be included to assistin understanding the present disclosure, however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Parametersidentified as “approximate” or “about” a specified value are intended toinclude both the specified value and values within 10% of the specifiedvalue, unless expressly stated otherwise. Further, it is to beunderstood that the drawings accompanying the present application may,but need not, be to scale, and therefore may be understood as teachingvarious ratios and proportions evident in the drawings. Moreover, whilevarious aspects, features and concepts may be expressly identifiedherein as being inventive or forming part of an invention, suchidentification is not intended to be exclusive, but rather there may beinventive aspects, concepts and features that are fully described hereinwithout being expressly identified as such or as part of a specificinvention, the inventions instead being set forth in the appendedclaims. Descriptions of exemplary methods or processes are not limitedto inclusion of all steps as being required in all cases, nor is theorder that the steps are presented to be construed as required ornecessary unless expressly so stated.

In the present disclosure, the term “vertical” is used to describe adirection substantially perpendicular to a base (or bottom) surface ofthe fluid component body, and the term “horizontal” is used to describea direction substantially parallel to the base surface of the fluidcomponent body. It is to be understood that the fluid component body maybe mounted or arranged in any suitable orientation (e.g., with the basesurface of the fluid component body extending substantially vertically,or at some other angle).

FIG. 1 illustrates an exemplary conventional three-valve manifold 10having a manifold body block 20 and diaphragm valves 30 installed incorresponding valve cavities 21 machined in the body block 20. Eachvalve cavity 21 includes a recessed surface or trepan 22 and a bore wall23 (FIG. 1A), with at least first and second ports 24, 26 provided inthe recessed surface 22.

Referring to the cross-sectional view of FIG. 2, each valve 30 includesa valve subassembly 40 and an actuator 50. The exemplary valvesubassemblies 40 each include a flexible diaphragm 41 and an annularseat carrier 42 received in the valve cavity 21 and including a lowerseal portion 44 that seals against the recessed surface 22 around thefirst port 24 and an upper seal portion 45 that seals against thediaphragm 41 when the diaphragm is moved to the closed position. Athreaded retainer 46 is installed in the valve cavity 21 to clamp theseat carrier 42 and diaphragm 41 against the recessed surface 22, withan outer male threaded portion of the retainer 46 mating with an innerfemale threaded portion of the bore wall 23. A male threaded bonnetportion 51 of the actuator 50 is threaded into a female threaded portionof the retainer 46 to connect the actuator 50 with the valve subassembly40 and to position the actuator stem 52 for operative engagement (e.g.,using intermediary button 54) with the diaphragm 41. A similar actuatedvalve assembly is shown and described in co-owned U.S. Pat. No.9,863,542 (the “'542 Patent”), the entire disclosure of which isincorporated herein by reference.

According to an aspect of the present application, a multi-valvemanifold body may be formed as a plurality of discrete valve bodysegments and conduit segments integrated into a single-piece, monolithicconstruction having a reduced size, weight, and raw material usage ascompared to a corresponding manifold body block. FIGS. 3-3J illustratesan exemplary three-valve manifold body 100 corresponding to (but notfunctionally identical to) the three-valve manifold body block 20 ofFIG. 1A. As shown, the manifold body 100 includes a plurality of valvebody segments 110 a, 110 b, 110 c each having an upper perimeter wallportion 111 a, 111 b, 111 c defining a valve cavity 112 a, 112 b, 112 c,and a lower base portion 114 a, 114 b, 114 c defining central flow ports116 a, 116 b, 116 c and offset flow ports 117 a, 117 b, 117 c.

The manifold body 100 further includes a plurality of conduit segments120 a, 120 b, 120 c, 120 d having first leg (e.g., vertical) portions121 a, 121 b, 121 c, 121 d defining conduit end portions or tube ends123 a, 123 b, 123 c, 123 d for connection to fluid system components(e.g., conduits) in the fluid system (e.g., by welding or conduitfittings), and extending to second leg (e.g., horizontal) portions 122a, 122 b, 122 c, 122 d extending to the flow ports 116 a, 116 b, 116 c,117 a, 117 b, 117 c. In an exemplary embodiment, a fitting connector(e.g., a VCR® metal gasket face seal fitting gland) may be welded to thetube stub to facilitate connection with a fluid system.

While the conduit end portions 123 a, 123 b, 123 c, 123 d of theillustrated embodiment extend substantially vertically upward, in otherembodiments, the conduit end portions may extend in other directions,including, for example, at an upward non-vertical angle, horizontally,vertically downward, or at a downward non-vertical angle. Further, whilesuch conduit end portions may be fabricated to extend in suchdirections, in other embodiments, the conduit end portions may befabricated to extend in a first direction (e.g., vertically upward), andthen be bent to extend in a second direction (e.g., horizontally). Theconduit end portions may be specifically fabricated to facilitate suchbending. For example, the conduit end portion may be formed orfabricated to have a reduced wall thickness on the portions of theconduit end portion subject to bending (e.g., at the axial location ofthe bend, and/or in the direction of the bend). As another example, theconduit end portion may be provided with a cross-sectional shapeselected to facilitate bending—for example, an oblong or high aspectratio cross-section (e.g., oval-shaped) having a minor diameter orientedin the direction of the intended bend. As yet another example, anexternal surface of the fluid component body may be provided with abending limit feature, such as, for example, a boss, wall, protrusion,or other body structure sized and positioned to limit bending of theconduit end portion to a desired angle (e.g., by abutting an outersurface of the conduit end portion at the desired angle).

In the illustrated embodiment, surrounding each central flow port 116 a,116 b, 116 c is an annular seating portion 115 a, 115 b, 115 c againstwhich a valve seat component may be sealed. While many different valvesubassemblies may be utilized, in an exemplary embodiment, the valvecavities 112 a, 112 b, 112 c and seating portions 115 a, 115 b, 115 cmay be configured to accommodate the valve 40 and actuator 50 assembliesof the embodiment of FIGS. 1 and 2, and/or the valve and actuatorassemblies of the above-incorporated '542 Patent, with the perimeterwall portions 111 a, 111 b, 111 c including female threaded portions formating with male threaded portions of a seat carrier retaining insert.

Adjacent perimeter wall portions 111 a, 111 b, 111 c of adjacent valvebody segments 110 a, 110 b, 110 c may be joined or fused together, forexample, to facilitate manufacturing, to reduce overall size of themanifold body 100 and/or to strengthen or reinforce these wall portions.While the conduit end portions 123 a, 123 b, 123 c may be similarlyjoined with one or more adjacent perimeter wall portions 111 a, 111 b,111 c, in the illustrated embodiment, the conduit end portions arespaced apart from the perimeter wall portions, and extend above an uppersurface of the perimeter wall portions, to facilitate connection to thesystem (e.g., by welding or conduit fittings), for example, by allowingfor lateral movement of the conduit end portions to accommodatetolerance deviations.

The base portions 114 a, 114 b, 114 c may be tapered (e.g., to have anouter diameter smaller than an outer diameter of the perimeter wall),for example, to reduce material usage and/or to provide clearance forone or more of the horizontal flow path portions 121 a, 121 b, 121 c,121 d, such that a horizontal flow path portion of a conduit segment isat least partially laterally aligned with the valve cavity of at leastone of the valve segments.

Many different porting arrangements may be provided. In the illustratedembodiment, branch conduit segments 120 a, 120 b, 120 c connect withcorresponding ones of the offset flow ports 117 a, 117 b, 117 c, andcommon conduit segment 120 d connects with each of the central flowports 116 a, 116 b, 116 c, for example, to provide a three-componentmixing arrangement, or a distribution arrangement.

Many different manifold body configurations may be provided, including,for example, manifold bodies accommodating different numbers of valveassemblies. Additionally, many different manifold body configurationsmay be provided, including, for example, manifold bodies accommodatingdifferent numbers of valve assemblies, such as, for example, the valveand actuator assemblies of FIGS. 1 and 2, and/or the valve and actuatorassemblies of the above incorporated '452 Patent.

In the manifold body 100 of FIGS. 3-3J, apertured mounting bosses 101are provided to facilitate mounting of the manifold within a system(e.g., to a plate or other such base component of a fluid system). Asshown, the mounting bosses may be joined or fused with an adjacentperimeter wall portion 111 a, 111 c to facilitate manufacturing, toreduce overall size of the manifold body 100 and/or to strengthen orreinforce these joined portions. The mounting bosses 101 mayadditionally be provided with tapers and/or counterbores, for example,to facilitate centering the head of the installed fastener (e.g.,mounting screw, not shown).

In other exemplary embodiments, the manifold body may be adapted forother types of mounting or installation arrangements. For example, themanifold body may be formed as an end plate or lid, for example, for acanister, to provide for sampling, purging, or other such fluid controlto and/or from the canister. FIGS. 4-4J illustrate an exemplaryfive-valve manifold body 300 (for use, for example with the valve andactuator assemblies of FIGS. 1 and 2, or the valve and actuatorassemblies of the above incorporated '452 Patent), having a lower plateor lid portion 305 sized to be welded or otherwise sealed to an open endof a canister (not shown). As shown, the manifold body 300 includes fivevalve body segments 310 a-e each having an upper perimeter wall portion311 a-e defining a valve cavity 312 a-e, and a lower base portion 314a-e joined with the lower plate 305 and defining central flow ports 316a-e (with surrounding seating portions 315 a-e) and offset flow ports317 a-e, 318 c-d, and a plurality of conduit segments 320 a-h (bestshown in FIG. 4J) extending from the flow ports 316 a-e, 317 a-e.

In the exemplary arrangement, first and second conduit segments 320 a,320 b are defined by vertical passages 321 a, 321 b through the lowerplate 305 from central flow ports 316 a, 316 b of first and second valvesegments 310 a, 310 b to a lower surface 306 of the lower plate (e.g.,for extraction of fluid samples from the canister). A third conduitsegment 320 c extends from an offset port 317 a of the first valvesegment 310 a to a central port 316 c of a third valve segment 310 c,with a horizontal portion 322 c of the conduit segment 320 c beingpartially disposed in the lower plate 305. A fourth conduit segment 320d extends from an offset port 317 b of the second valve segment to acentral port 316 d of a fourth valve segment 310 d, with a horizontalportion 322 d of the conduit segment 320 d being partially disposed inthe lower plate 305. A fifth conduit segment 320 e extends from anoffset port 317 c of the third valve segment 320 c to a central flowport 316 e of a fifth valve segment 310 e, with a horizontal portion 322e of the conduit segment 320 e being partially disposed in the lowerplate 305. A sixth conduit segment 320 f extends from an offset port 317e of the fifth valve segment 310 e to an offset port 317 d of the fourthvalve segment 310 d, with a horizontal portion 322 f of the conduitsegment 320 f being partially disposed in the lower plate 305. A seventhconduit segment 320 g includes a horizontal portion 322 g extending froma second offset port 318 c of the third valve segment 310 c, andpartially disposed in the lower plate 305, to a vertical end portion 321g extending upward from the lower plate 305 and defining a conduit endportions 323 g providing an inlet/outlet port for connection to fluidsystem components (e.g., conduits) in the fluid system (e.g., by weldingor conduit fittings). An eighth conduit segment 320 h includes ahorizontal portion 322 h extending from a second offset port 318 d ofthe fourth valve segment 310 d, and partially disposed in the lowerplate 305, to a vertical end portion 321 h extending upward from thelower plate 305 and defining a conduit end portions 323 h providing aninlet/outlet port for connection to fluid system components (e.g.,conduits) in the fluid system (e.g., by welding or conduit fittings).

As shown, a supply/drain port 328 may be provided with a passage 329through the lower plate, for example, for quick filling or drainage ofthe canister. The port 328 may be plugged or otherwise sealed duringnormal operation of the canister.

Adjacent perimeter wall portions 311 a-e of adjacent valve body segments310 a-e may be joined or fused, for example, to reduce overall size ofthe manifold body 300 and/or to strengthen or reinforce these wallportions. While the conduit end portions 323 g, 323 h may be similarlyjoined with one or more adjacent perimeter wall portions 311 a-e, in theillustrated embodiment, the conduit end portions are spaced apart fromthe perimeter wall portions, and extend above an upper surface of theperimeter wall portions, to facilitate connection to the system (e.g.,by welding or conduit fittings), for example, by allowing for lateralmovement of the conduit end portions to accommodate tolerancedeviations. The base portions 314 a-e may be tapered, for example, toreduce material usage and/or to provide clearance for one or more of thehorizontal flow path portions.

The overall shape and internal flow path arrangements of a fluidcomponent body (e.g., a manifold body) may make the body difficult tomanufacture using conventional machining, molding, or castingtechniques. According to an aspect of the present disclosure, a fluidcomponent body, for example, the manifold bodies 100, 300 of FIGS. 3-3Jand 4-4J, may be fabricated using additive manufacturing to produce amonolithic body having discrete, but partially joined or fused, valvesegments and conduit segments. Examples of additive manufacturingtechniques that may be utilized include, for example: laser powder bedfusion (direct metal laser sintering or “DMLS,” selective lasersintering/melting or “SLS/SLM,” or layered additive manufacturing or“LAM”), electron beam powder bed fusion (electron beam melting or“EBM”), ultrasonic additive manufacturing (“UAM”), or direct energydeposition (laser powder deposition or “LPD,” laser wire deposition or“LWD,” laser engineered net-shaping or “LENS,” electron beam wiredeposition). Providing a manifold body as a single, monolithic componentmay eliminate assembly costs, reduce component wear, reduce adverseeffects from heat cycling, improve corrosion behavior (galvanic effects,crevice, stress corrosion cracking), and reduce lead time tomanufacture. Further, fabrication using additive manufacturing mayreduce the amount of raw material used, and may reduce the size andweight of the finished body.

While the conduit end portions 323 g, 323 h of the illustratedembodiment extend substantially vertically upward, in other embodiments,the conduit end portions may extend in other directions, including, forexample, at an upward non-vertical angle, horizontally, verticallydownward, or at a downward non-vertical angle. Further, while suchconduit end portions may be fabricated to extend in such directions, inother embodiments, the conduit end portions may be fabricated to extendin a first direction (e.g., vertically upward, horizontally), and thenbe bent to extend in a second direction (e.g., horizontally,vertically). For example, for components having significantlongitudinal, lateral, and vertical dimensions, 3D printing or otheradditive manufacturing can be more time consuming and more costly.According to an aspect of the present disclosure, a 3D printed fluidcomponent extending primarily in first and second dimensions (e.g.,longitudinal and lateral) may be configured to have one or more portions(e.g., one or more end ports or connecting ports) bent to extendprimarily or significantly in a third dimension (e.g., vertical),thereby providing a finished fluid component having significantlongitudinal, lateral, and vertical dimensions while reducing 3Dprinting time and cost.

The conduit end portions may be specifically fabricated to facilitatesuch bending. For example, the conduit end portion may be formed orfabricated to have a reduced wall thickness on the portions of theconduit end portion subject to bending (e.g., at the axial location ofthe bend, and/or in the direction of the bend). As another example, theconduit end portion may be provided with a cross-sectional shapeselected to facilitate bending—for example, an oblong or high aspectratio cross-section (e.g., oval-shaped) having a minor diameter orientedin the direction of the intended bend. As still another example, a portor conduit portion formed to be bent in a post-fabrication operation maybe shaped and/or orientated to promote a hinging action for desiredbending of the conduit. As yet another example, an external surface ofthe fluid component body may be provided with a bending limit feature,such as, for example, a boss, wall, protrusion, or other body structuresized and positioned to limit bending of the conduit end portion to adesired angle (e.g., by abutting an outer surface of the conduit endportion at the desired angle).

FIG. 5 illustrates an exemplary port or conduit 500 of a 3D printedfluid component. The conduit 500 includes first and secondlongitudinally extending portions 512, 522, first and second verticallyextending portions 515, 525, and a U-shaped portion 530 connecting thevertically extending portions. The longitudinally extending portions512, 522 may extend to other portions of the fluid component (asschematically represented at 511 and 521 in FIG. 5A), such as valvebodies or end fittings. The vertically extending portions 515, 525 areprovided with an oblong or high aspect ratio cross-section (e.g.,oval-shaped) to facilitate bending of the second longitudinallyextending portion into an orientation substantially orthogonal to thefirst longitudinally extending portion, as shown in FIGS. 5A and 6. Inanother embodiment (not shown), the port may additionally oralternatively include a U-shaped portion having an oblong or high aspectratio cross-section (e.g., oval-shaped) to facilitate bending at theU-shaped portion.

According to another aspect of the present disclosure, one or morecross-sectional portions (e.g., oblong cross-sectional portions, asdescribed herein) of a 3D printed conduit may be fabricated withinternal supports (e.g., an internal lattice) configured to maintain theshape of the conduit portion during 3D printing and/or bending. Once theconduit portion has been bent to a desired configuration, the internalsupports may be removed, for example, by using abrasive flow machining(AFM), by which an abrasive-laden fluid is pumped through the conduit tobreak or erode away the internal supports. Alternatively, the internalsupports may be removed (e.g., by AFM, as discussed above) prior tobending, for example, to provide for greater flexibility of the conduit.FIG. 7 illustrates an exemplary cross-section of an oblong conduitportion 508 including internal lattice supports 509.

The conduit or port may be bent using tools configured to bend thesecond longitudinal portion, with respect to the first longitudinalportion, to a consistent desired orientation (e.g., substantiallyorthogonal). In other embodiments, the fluid component may be providedwith one or more external stop portions configured to provide a positivestop to the bending operation when the longitudinal portions havereached the desired bent orientations. In the embodiment of FIGS. 5 and6, first and second stop portions 514, 524 extend from exterior surfacesof the longitudinal conduit portions and are sized to contact exteriorsurfaces of the U-shaped conduit portion 530 (as shown in FIG. 6) whenthe vertical conduit portions 515, 525 have bent to position thelongitudinal conduit portions 512, 522 in the desired orientation. Insome embodiments, the stop portions may be sized or positioned to allowfor slight over-bending beyond the desired orientation, for example, toaccount for spring back inherent in the material used (e.g., stainlesssteel or other metals).

Still other arrangements may be utilized to facilitate conduit bendingto a desired limit. FIGS. 8 and 9 illustrate an exemplary 3D printedconduit 600 having first and second longitudinal portions 612, 622 and acentral bending portion 630 having a reduced wall thickness tofacilitate bending, and a row of spaced apart protrusions 631, disposedalong a surface intended to be the inner diameter of the bend, thatengage each other (see FIG. 9) at a desired bend orientation (e.g.,approximately 90°), including adjacent stop portions 632 (see FIG. 8A)that engage each other to provide a controlled, uniform bend with anengineered bend radius, thereby preventing kinking or other bendingartifacts that may result from a non-uniform bend. In some embodiments,the stop portions 632 may be sized or positioned to allow for slightover-bending beyond the desired orientation, to account for spring backinherent in the material used (e.g., stainless steel or other metals).

According to another aspect of the present application, additionalfeatures or arrangements may be provided to secure the bent conduit inthe desired configuration. For example, contacting external surfaces(e.g., conduit surfaces and stop portions) may be joined or fused (e.g.,tack-welding or adhesive) to secure the conduit in the desired bentposition. As another example, external structural features may beprovided to effect a press fit, snap-fit or mating engagement in thedesired bent condition. FIG. 10 illustrates an exemplary 3D printedconduit 700, similar to the conduit 600 of FIGS. 8 and 9, havingsnap-fit latch portions 714, 724 extending from the first and secondlongitudinal portions of the conduit. When the conduit 700 is bent tothe desired configuration, the latch portions 714, 724 snap intointerlocking engagement with each other to secure the bent conduit inthe desired configuration. While the conduit 700 is shown with spacedapart bend controlling protrusions 731, similar to the protrusions 631of the conduit 600 of FIGS. 8 and 9, in other embodiments, bendableconduits having snap-fit latch portions may be provided withoutadditional bend limiting features, or with different bend limitingfeatures.

In addition to accommodating different valve and/or conduit segmentarrangements in a fluid component body, as described above, additivemanufacturing of the fluid component body may facilitate incorporationof additional features. For example, additive manufacturing may beutilized to produce one or more internal flow paths in a fluid componentbody that are configured to include one or more flow pathdiscontinuities along one or more legs of the internal flow path,including, for example, deviations in flow path cross-sectional shape,cross-sectional size, flow path center line, and internal surfacecharacteristics. Many different types of flow path discontinuities maybe provided to facilitate a variety of flow conditions.

By way of example, in some applications, fluid system flow paths requirea very smooth or highly polished surface finish, for example, tominimize the generation of particle contamination or fluid entrapment.For long and/or complex (non-straight) flow paths (e.g., theelbow-shaped flow path 400 of FIG. 11), polishing may be accomplishedusing abrasive flow machining (AFM) or abrasive flow finishing (AFF), bywhich an abrasive-laden fluid is pumped through a workpiece to remove orerode surface material from rough internal flow path surfaces to producesmoother, polished surfaces. This process can be relatively inefficient,particularly for long, straight cylindrical flow paths which limit theshear action of the abrasive fluid along the flow path walls. Accordingto an aspect of the present disclosure, extended internal flow paths maybe adapted to provide flow path discontinuities configured to provideincreases in one or more of flow shear, flow compression, and flowincidence for accelerated erosion of the flow path surfaces. In someapplications, a first portion of the flow path (e.g., a first leg orvertical portion 410 of the flow path 400) may extend to an externalsurface of the fluid component body and may be more easily accessed byconventional mechanical polishing techniques, and therefore may beprovided without flow path discontinuities along certain portions of theflow path, with the discontinuities being limited to, or concentratedin, a second portion of the flow path (e.g., a horizontal or second legportion 420 of the flow path 400).

Many different types of flow path discontinuities may be provided inaccordance with the present disclosure. As one example, a flow path maybe provided with a varying cross-sectional shape, for example, toincrease the shear action of the abrasive laden fluid against the flowpath walls. The cross-sectional shape of the flow path may be variedbetween two or more suitable shapes, including, for example, circular,oval, square, rectangular, and triangular, as well as more complexshapes, including a teardrop shape. FIG. 12 illustrates an exemplaryelbow shaped flow path 400 a having a circular cross-section at a firstcross-sectional plane 411 a (e.g., along the first leg flow path portion410 a) and a teardrop cross-section at a second cross-sectional plane421 a (e.g., along the second leg flow path portion 420 a), with thetransition from circular to teardrop cross-section occurring along thebend in the elbow. In the exemplary manifold body 100 of FIGS. 3-3J,horizontal flow path portions 122 a, 122 d are provided with a similarteardrop-shaped cross-section, as shown in FIG. 3I. In otherembodiments, additional or alternative cross-sectional shape changes maybe provided, for example, along the length of the first leg flow pathportion 410 a and/or along the length of the second leg flow pathportion 420 a. A flow path of varying cross-sectional shape may, butneed not, be configured to have a substantially constant cross-sectionalarea along the length of the flow path, for example, to maintain thedesired flow properties while providing increased shear action againstthe flow path walls as a result of the changing cross-sectional shape.

In another exemplary embodiment, a flow path may be provided with avarying cross-sectional area, for example, to increase compression ofthe abrasive laden fluid at the smaller cross-sectional area (or “neckeddown”) portions, to increase the erosive effects at or near these neckeddown portions. FIG. 13 illustrates an exemplary elbow shaped flow path400 b having first leg and second leg flow path portions 410 b, 420 bwith varying cross-sectional areas at various cross-sectional planes 411b, 412 b, 421 b, 422 b along the length of the flow path 400 b. In theillustrated embodiment, the first leg flow path portion 410 b varies incross-sectional area between a maximum area cross-sectional plate 411 band a minimum area cross-sectional plane 412 b, and the second leg flowpath portion 420 b varies in cross-sectional area between a maximum areacross-sectional plate 421 b and a minimum area cross-sectional plane 422b. In other embodiments, portions of the flow path (e.g., the entirefirst leg flow path portion) may have a uniform cross-sectional area. Aflow path of varying cross-sectional size may, but need not, beconfigured to have a substantially constant cross-sectional shape (e.g.,circular) along the length of the flow path. Flow through the flow pathmay be primarily limited by the smallest cross-sectional area along thelength of the flow path, and the flow path may be sized accordingly.

In some such exemplary embodiments, longer flow channels in a fluidcomponent body may be configured to provide progressively restrictedflow in the direction of fluid flow (e.g., inlet to outlet, or inlet toport center point), for example, to improve the efficacy of abrasiveflow finishing. The internal surfaces may be gradually tapered radiallyinward, or more sharply tapered (e.g., stepped) radially inward, or by acombination of two or more types of flow path profiles. The desiredamount of flow path restriction may be based at least in part on therelative pressure loss of the abrasive laden fluid (which may be afunction of viscosity and frictional losses, for example, due toabrasive cutting forces), with more aggressive media (with higherpressure losses) potentially benefitting from more aggressive flow pathtapering. This restriction in flow area may be correlated to a length ofthe passage, for example, with the flow path area reduction beingquantified as a percentage reduction in area per inch of port length(e.g., 15%-30% per inch of port length).

In another exemplary embodiment, a flow path may be provided withnon-linear flow path portions having a varying center line (i.e.,non-coaxial), for example, to change direction of the flow path toaffect the angle of incidence of the abrasive laden fluid against thewalls of the flow path, to increase the erosive effects on the flow pathwalls. Many different types of non-linear flow paths may be utilized.FIG. 14 illustrates an exemplary elbow shaped flow path 400 c havingfirst leg and second leg flow path portions 410 c, 420 c with a curvedhelical flow path resulting in variations in the center line locationsat various cross-sectional planes 411 c, 412 c, 421 c, 422 c along thelength of the flow path 400 c. In the illustrated embodiment, the firstleg and second leg flow path portions 410 c, 420 c are provided withcontinuously varying center lines resulting from a continuous helicalpattern. In other embodiments, portions of the flow path (e.g., theentire first leg flow path portion) may have a constant center line(i.e., substantially linear). A flow path of varying cross-sectionalsize may, but need not, be configured to have a substantially constantcross-sectional shape (e.g., circular) and a substantially constantcross-sectional size along the length of the flow path.

In other embodiments, a flow path maybe provided with two or more of:(a) a varying cross-sectional shape, (b) a varying cross-sectional area,and (c) a varying center line. FIG. 15 illustrates an exemplary elbowshaped flow path 400 d having first leg and second leg flow pathportions 410 d, 420 d with varying cross-sectional shapes, areas, andcenter lines at various cross-sectional planes 411 d, 412 d, 421 d, 422d along the length of the flow path 400 d.

Additive manufacturing of the fluid component body may facilitateincorporation of additional features. As another example, the internalflow path surfaces of a fluid component body may be textured to affectfluid flow properties, such as, for example, altering turbulent flowconditions and/or reducing the propensity for contaminants or processfluid adsorbing to the internal surfaces. As one example, a flow pathmay be formed with an internal surface provided with a pattern ofsurface discontinuities, such as, for example, dimples, raisedprotuberances, grooves, or other such surface features. These surfacediscontinuities may, for example, be quantified based on depth and/orsurface area (e.g., axial length, circumferential width, diameter) as apercentage of a flow path dimension, such as, for example, borediameter. In one such exemplary embodiment, a flow path internal surfaceis provided with an array of spherical dimples having a spherical radiusof approximately 1/10^(th) of the effective bore diameter, and a dimpledepth of approximately 1/50^(th) of the effective bore diameter. Suchdimples may, for example, be spaced to achieve approximately 50% surfacedensity on the bore inner diameter.

As another example, additive manufacturing may be utilized to provideportions of the flow path(s) that are layered with a material ormaterials having a desired thermal conductivity, corrosion resistance,hardness, or other such properties.

The inventive aspects have been described with reference to theexemplary embodiments. Modification and alterations will occur to othersupon a reading and understanding of this specification. It is intendedto include all such modifications and alterations insofar as they comewithin the scope of the appended claims or the equivalents thereof.

We claim:
 1. A method of fabricating a fluid component body, the methodcomprising: forming a monolithic fluid component body including a valvesegment having an annular upper perimeter wall portion defining a valvecavity and a lower base portion defining first and second flow ports,and a conduit segment extending from one of the first and second flowports and including a conduit end portion defining a tubular portionextending in a first direction and spaced apart from a remainder of thefluid component body; and bending the conduit end portion from the firstdirect to a second direction.
 2. The method of claim 1, wherein thefirst direction is substantially vertical and the second direction issubstantially horizontal.
 3. The method of claim 1, wherein the conduitend portion has a reduced wall thickness at an axial location of thebend.
 4. The method of 1, wherein the conduit end portion has a reducedwall thickness at a circumferential location corresponding to thedirection of the bend.
 5. The method of claim 1, wherein the bodyincludes a bending limit feature on an external surface of the bodysized and positioned to limit bending of the conduit end portion to adesired angle, wherein bending the conduit end portion from the firstdirect to a second direction comprises bending the conduit end portionuntil an outer surface of the conduit end portion abuts the bendinglimit feature.
 6. The method of claim 1, wherein the conduit end portionhas an oblong cross-section having a minor diameter oriented in adirection of the bend.
 7. The method of claim 1, wherein forming themonolithic fluid component body comprises using additive manufacturing.8. A method of fabricating a fluid component, the method comprising:forming, using additive manufacturing, a conduit having first and secondportions connected by a central portion; bending the central portion ofthe conduit to reorient the second portion of the conduit with respectto the first portion of the conduit.
 9. The method of claim 8, whereinbending the second portion of the conduit comprises orienting the secondportion of the conduit substantially perpendicular to the first portionof the conduit.
 10. The method of claim 8, wherein the conduit includesat least a first bending limit feature on an external surface of theconduit sized and positioned to limit bending of the conduit end portionto a desired angle, wherein bending the conduit end portion comprisesbending the conduit end portion until the first bending limit featureabuts a portion of the conduit.
 11. The method of claim 10, whereinbending the conduit end portion comprises bending the conduit endportion until the first bending limit feature abuts a second bendinglimit feature.
 12. The method of claim 11, wherein the first and secondbending limit features comprise protrusions on an outer surface of theconduit along an inner bend diameter.
 13. The method of claim 8, whereinforming the conduit comprises forming the central portion with an oblongcross-section having a minor diameter oriented in a direction of thebend.
 14. The method of claim 13, wherein forming the conduit furthercomprises forming internal supports within the oblong cross-section. 15.The method of claim 14, further comprising removing the internalsupports before bending the central portion of the conduit.
 16. Themethod of claim 14, further comprising removing the internal supportsafter bending the central portion of the conduit.
 17. The method ofclaim 8, wherein prior to bending, the first and second portions aresubstantially colinear.
 18. The method of claim 8, further comprisingsecuring the first and second portions in a desired bent orientationusing at least one of tack-welding, adhesive, and interengagingstructural features provided to effect one of a press fit, snap-fit, ormating engagement.
 19. The method of claim 8, wherein bending thecentral portion of the conduit comprises overbending beyond a desiredorientation and allowing the material to spring back to the desiredorientation.
 20. A fluid component body comprising a monolithic fluidcomponent body including a valve segment having an annular upperperimeter wall portion defining a valve cavity and a lower base portiondefining first and second flow ports, and a conduit segment extendingfrom one of the first and second flow ports and including a conduit endportion defining a tubular portion extending in a first direction andspaced apart from a remainder of the fluid component body, wherein theconduit end portion is bent from the first direct to a second direction;and wherein the conduit end portion is secured in a desired bentorientation using at least one of tack-welding, adhesive, andinterengaging structural features provided to effect one of a press fit,snap-fit, or mating engagement.